Energy 35 (2010) 3738e3750

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Energy
journal homepage: www.elsevier.com/locate/energy

Optimizing the energy efficiency of conventional multi-cylinder dryers in the

paper industry
Jobien Laurijssen a, *, Frans J. De Gram a, b, c,1, Ernst Worrell b, c, Andre Faaij c
a
Centre of Competence Paper and Board, Ijsselburcht 3, 6825 BS Arnhem, The Netherlands
b
Ecofys, PO Box 8408, NL-3503 RK Utrecht, The Netherlands
c
Department of Science, Technology and Society, Copernicus Institute, Utrecht University, Van Unnikgebouw, Heidelberglaan 2, 3584 CS Utrecht, The Netherlands

a r t i c l e i n f o a b s t r a c t

Article history: The paper industry is, with about 6% of the total worldwide industrial energy use, an energy-intensive
Received 23 November 2009 industry. The drying section is with approximately 50% the largest energy consumer in a paper mill,
Received in revised form energy use in this section is mainly heat use. Several options to decrease heat use in conventional multi-
15 April 2010
cylinder drying sections are investigated, calculating the effect on energy use. Optimization measures
Accepted 17 May 2010
Available online 1 July 2010
include a) decreasing the amount of water evaporation by applying additives in higher consistencies and
by lowering the water viscosity, b) decreasing the heat use of water evaporation by increasing the dew
point temperature of the dryer and c) increasing the amount of heat recovery by using exhaust air to not
Keywords:
Energy efficiency
only pre-heat the incoming air but also to increase process water temperatures. These could all be
Paper industry achieved by retrofitting and/or choosing different processing conditions in existing factories. The
Multi-cylinder dryers combined thermal heat saving potential due to the optimization actions is 1.3 GJh/t paper (or 32% of the
Heat recovery drying section’s heat use) as compared to the reference situation.
Ó 2010 Elsevier Ltd. All rights reserved.

1. Introduction The pulp and paper industry is composed of two interconnected

Globally, the pulp and paper industry is the fourth largest
industrial energy user. With 6.4 EJ in 2005 it is responsible for
about 6% of total world industrial energy use [1]. Approximately
two-thirds of the final energy consumption is fuel used to produce
heat, while the remaining third is electricity, either purchased or
self-generated [1]. Unlike most other industrial sectors, the pulp
and paper industry also produces energy as a by-product and
currently generates about 50% of its own energy needs from
biomass residues [2]. The significant use of biomass means that the
CO2 intensity is lower than other energy intensive industries [1].
Since energy prices have risen drastically by around 40% between
2004 and 2007 in Europe [3], energy has become one of the key
cost components of the pulp and paper sector. Energy accounted for
19% of total operating costs of the European pulp and paper
industry in 2005, compared to 15% in 2001, which is a difference of
more than 10 billion euro [3]. In 2008, the share of energy in the
total production costs was up to 30% for some mills [4].
* Corresponding author. Tel.: þ31 (0) 26 365 35 16; fax: þ31 (0) 26 365 35 20.
E-mail address: j.laurijssen@kcpk.nl (J. Laurijssen).
1
Retired.
sub-sectors: pulp and papermaking, which can either be integrated
within a single mill or separated into two. In pulp production, the
raw material, mainly wood, is transformed into pulp. Paper
production basically consists of 5 steps:
1. Stock preparation where pulp is mixed with water and additives
and is prepared (e.g. cleaned, de-inked, refined) to obtain the
right properties.
2. In the former (or wire) section the first water is removed by
gravitational forces and vacuum.
3. After the former section, the wet paper web enters the press
section where further water removal takes place mechanically.
Dry solid content after the press section is 33e55% depending
on paper grade and press section design [5].
4. Remaining water is removed thermally in the first drying (or
pre-drying) section. Depending on end product specifications,
paper is mostly treated further with a sizing step e.g. coating,
glue or starch.
5. In this case a second drying (or final drying) step is needed. A
small amount of moisture (5e9%) remains in the paper even
after drying [5].
Although the basic principle of all paper machines is similar (i.e.,
wire, press, and dryer sections) there are differences in the design

0360-5442/$ e see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.energy.2010.05.023
 J. Laurijssen et al. / Energy 35 (2010) 3738e3750
of individual components, mainly associated with the type of paper
produced [6]. By far the largest share of energy use in a non-inte-
grated paper mill2 is in the drying sections (see Fig. 1). Thermal
drying is often responsible for more than 80% of the total steam use.
The paper machine drying section and its operating principal have
remained almost unchanged since their initial development;
contact drying with steam heated cylinders is still the dominant
method for drying paper and board [5]. Attempts to develop new
drying techniques with reduced energy intensity in the paper
industry are, however, known. Among these novel drying tech-
niques are impulse, impingement, through-air and condensing belt
drying. Table 1 compares the distribution of different drying
methods in paper and board drying applications, energy
consumption of the methods, evaporation intensities and effect on
paper qualities. In a study by De Beer et al. [7] several of these
technologies are discussed. Most of these technologies are,
however, not available commercially yet [7e10].
Impulse drying improves mechanical dewatering by applying
high temperatures in the press nip, thereby reducing water evap-
oration in the drying section and hence energy consumption. The
paper is pressed between a very hot rotating roll and a static
concave so that web consistency can be increased to 55e78%. The
impulse dryer can be retrofitted into an existing machine or
incorporated into new ones. The technology was invented by
Wahren in 1970, and was further developed together with a paper
machine manufacturer (Beloit) in the 80s and 90s. In between 1989
and 1999 four attempts to commercialize the technology failed [8].
Under Swedish governmental support a major R&D program was
started at the end of the 90s. The main argument for developing the
technology further became the increased machine capacity and
reduced capital intensity in new mills. The original claim of
increased dewatering lost strength over time [8]. After more than
25 years of R&D activities and 15 years of government R&D support
impulse drying is still no proven technology [8].
In impingement drying, heat is carried into the web using hot,
dry air. Due to the high temperature difference between air and
web, there is a high heat flux and consequent high drying rate. Gas
burners heat up the air in commercial installations. It is also
possible to combine power production with the production of hot
gas for the drying unit [11]. Air impingement dryers (Yankee
cylinders) are commercial available and are largely used in e.g.
tissue production (84% see Table 1). The advantage of this tech-
nology is the large increase in drying (evaporation) rate (see Table
1). Total energy requirement for air impingement drying is more or
less similar to conventional multi-cylinders [11,5].
Next to air impingement, also steam impingement dryers are
known. They are comparable to air impingement dryers but differ
in drying medium, as superheated steam is used instead of hot air.
Energy use is more or less similar to conventional multi cylinder
drying [7]. However, since the exhaust air is (low pressure) steam, it
is possible to recover all latent heat which creates large potential
for heat recovery. In order to compensate for pressure drops,
a compressor or fan is required which causes an increase in elec-
tricity use. Even though the concept of superheated steam drying is
more than 100 years old, and the technology is already used in
other industries, the technology is still not commercial in the paper
industry [12] as implementation requires a major adaptation to the
paper making process [7].
Through-air drying (TAD) is a commercially available tech-
nology that has significant market share (11% see Table 1) in tissue
2
Non-integrated paper mills are paper mills without a pulp production facility.
These mills use market pulp to produce paper. Integrated mills have a pulp mill on-
site. These mills use logs or chips to produce paper.
3739
Fig. 1. Distribution of total primary energy use in a specific paper mill.
drying. In the TAD process, hot process air flows through the sheet
past each individual fibre. This makes the process much more
efficient than conventional drying techniques [5]. However,
because there is no wet pressing in a TAD machine, increased water
evaporation is needed in the dryer. TAD machines need to remove
about two times more water per unit of fibre by thermal energy
than conventional machines. Even though the drying process itself
is more efficient, energy intensity increases [5]. The main advan-
tages of the technology are enhanced sheet properties of softness,
bulk and absorbance.
In condensing belt (Condebelt) drying, paper is dried in a drying
chamber by contact with a continuous hot steel band, heated by gas
or steam. Vapour travels through wire gauzes and condensates on
a cooled steel band on the other side. The technology has been
developed by Valmet and R&D has been conducted since 1975. Its
main advantage is the increased drying rate (5e15 times) and the
potential to completely replace the drying section of conventional
machines. Only three commercial installations have been built: the
first one in Finland in 1996, the latest two in South Korea in 1999
and 2003. After all these years, the technology is still in early
commercialization phase. Steam savings are expected to be 10e20%
while electricity use is expected to remain the same [9].
It is not expected that large scale implementation of novel
dryers will be rapid, as the need for new drying hardware is limited
due to the long life-cycle of drying equipment (20e40 years) [10].
Paper manufacturing is very capital-intensive and presently, state-
of-the-art PMs may cost more than US$ 400 million apiece and
typically account for over 50% of the total investment costs of new
paper mills [6]. A major new technology is introduced only once in
five to seven years and in order to stay cost-competitive, a paper
machine has to be rebuilt on average once every 15 years [13].
Summarizing, the share of conventional multi-cylinder dryers is
85e90%, and in paper production even 95% (see Table 1). Only a few
novel drying technologies are commercial and the energy-effi-
ciency of those technologies is often worse than the efficiency of
conventional dryers. Since energy efficiency is crucial, the goal of
this study is to identify short-term energy improvement options in
conventional multi-cylinder dryers in the paper industry. Few
studies are known that focus on improvements of conventional
dryers in the paper industry (e.g. [14e17]). Though most of them
focus solely on improvements in the heat recovery system. Ther-
modynamic (or exergy) analysis for energy optimization is also
known in other industries with significant heat use, see for example
[18e20]. In this study, we perform a thermodynamic optimization
of ventilation systems of conventional multi-cylinder dryers.
Moreover, we identify measures to reduce evaporation in the first
place. We calculate the net energy savings that can be achieved. We
will not focus on economic aspects of the optimization options.
3740 J. Laurijssen et al. / Energy 35 (2010) 3738e3750

Table 1
Paper industry dryer distribution by application (Source: [5]).

Dryer; application Industry Grades Distribution Energy use Drying rate Paper quality
share (%)a (%) (MJ/kg H2O) (kg H2O/hm2) (þ, w,)b
Multi-cylinder; Printing, 85e90 Tissue 5 2.8e4.0 20 w
base papers & boards Paper 95 2.8e4.0 20 þ
Board 95 2.8e4.0 15 þ
Coating 35 3.0e4.5 5e10 w

Yankee; Soft tissues & boards 4e5 Tissue 84 4.0e5.0 200 þ

Paper 0
Board 3 2.8e3.5 30e50 þ
Coating 0

Infrared; Sizing & coating 3e4 Tissue 0

Paper 1 5.0e8.0 10e30 w
Board 1 5.0e8.0 10e30 w
Coating 15 5.0e8.0 70e120 w

Impingement; Increased capacity 2e3 Tissue 0

Paper 4 2.8e3.5 50e120 w
Board 0
Coating 50 3.0e5.0 40e140 w

Through; Soft tissues, filter fabrics 1e2 Tissue 11 3.4e4.5 170e550 þ

Paper 0
Board 0
Coating 0

Condebelt; In production scale Tissue

Paper
Board 1 2.6e3.6 200 þ,
Coating

Impulse; Pilot stage Tissue

Paper 0 0.55e1.4 500e8000 þ,
Board 0 0.55e1.4 500e8000 þ,
Coating
a
Pulp dryers excluded.
b
w indicates that quality might improve or worsen depending on paper grade.

Calculations are based on data from Dutch paper mills. The study
concerns a modeling exercise based on thermodynamic principles,
no real time experiments have been performed. In the next section,
we describe the paper drying process in multi-cylinder dryers. We
then present the methodology, including the theory behind energy
use of water evaporation. In the following section, we calculate the
effect of several optimizations to increase the energy efficiency of
paper drying. Finally, results will be discussed and conclusions will
be drawn.
air, which also determines the speed of diffusion. The hood exhaust
air has a high moisture content and a temperature of 80e90  C.
About 90e95% of the heat used in the process ends up in the
exhaust air [5], partly in the dry air and mostly in the diffused
vapor. The remaining heat is lost by radiation and convection in the
hood, and by heating up the paper web. The high energy content of
the exhaust air makes this stream very suitable for heat recovery.
The recovered heat is often used to heat supply air (HRC I), but also
the process water (HRC II) and the machine room heating circuit
(HRC III) can be supplied with heat from the exhaust air.

2. Paper drying in multi-cylinder dryers

In thermal drying of a product, we can distinguish three steps: HRC III Glycol for space heating

separation of liquid from the product, transition of liquid from Supply air:
a fluid to a gaseous phase and removal of the produced vapor. The HRC II Process water
manner and temperature at which these steps occur, largely
determine the energy efficiency of the drying process. Nowadays,
most paper mills have multi-cylinder drying sections with closed HRC I
hoods. In the hood, ventilation air can be largely controlled and is
supplied to those places where evaporation is highest. In Fig. 2,
HE
a schematic overview of a multi-cylinder dryer is shown. The dryer Exhaust air: Sizing
consist of two drying sections and a size press. The paper machine
cylinders are heated with steam. For removal of moisture, air of Pre-dryer Final dryer
approximately 95  C is supplied to the paper hood. Outside air is
Paper web
pre-heated in the first heat recovery unit (HRC I) and further heated
with steam. The evaporated water diffuses in the air surrounding
the cylinders. This air needs to be replaced continuously in order to
maintain a difference in vapor concentration between vapor at the
Steam Condensate
surface of the paper web and vapor in the air. The difference in
vapor concentration is proportional to the water vapor pressure at Fig. 2. Schematic overview of an example multi-cylinder dryer including heat
the paper web surface and the partial water vapor pressure in the recovery.
 J. Laurijssen et al. / Energy 35 (2010) 3738e3750
An important variable in paper drying is the dewpoint. Hood
manufacturers typically give guaranteed design values for paper
hood dewpoints. This means that no condensation within the hood
takes place at temperatures above the dewpoint. The higher the
dewpoint the easier condensation occurs which is a phenomenon
paper producers want to avoid. On the other hand, the higher the
dewpoint, the more vapour the drying air can contain. Which
means that less drying air is needed to remove evaporated water.
Moreover, at higher dewpoint temperatures, it is possible to
recover more heat from the exhaust air.
3. Methodology
In this study, we focus on optimization options for state-of-the-
art multi-cylinder dryers with closed hoods. We further assume
that the hood is in good condition, has proper insulation and is
equipped with proper ventilation, air distribution and frequency
controlled fans. The energy use for paper web heating and the heat
loss due to convection and radiation (together approx. 5e10%) [5] is
not taken into account. This means that about 90e95% of the steam
consumption of the dryer is covered in this study.
The energy needed for paper drying can be determined by
a combination of:
1) the amount of water that needs to be removed in the drying
sections
2) the amount of energy needed for water evaporation
3) the amount of recovered heat from the exhaust air
3.1. Amount of water evaporation
The amount of water evaporation in the two drying sections can
be calculated as follows:
! to optimize heat recovery from exhaust air. In this study we account
100 100
PWEpd ¼   Pbdry
dmi dmapd
!
100 100
PWEfd ¼   Pbdry
dmifd dmo
where PWEpd ¼ Product Water Evaporation pre-dryer section (ton);
PWEfd ¼ Product Water Evaporation final-dryer section (ton); dmi
¼ Dry matter content paper web in (%); dmapd ¼ Dry matter content
paper web after pre-dryer section (%); dmifd ¼ Dry matter
content paper web in final dryer section (%); dmo ¼ Dry matter
content paper web out (%); Pbdry ¼ Bone dry mass of paper web
(ton).
3.2. Amount of energy needed for water evaporation
The energy needed to evaporate a kg of water can be determined
with a Mollier chart for humid air. The Mollier chart can be used to
make calculations on humid air conditions for processes at
a constant (atmospheric) pressure. A schematic overview of the
basic principles of the Mollier chart is shown in Fig. 3. The diagram
shows, by means of continuous lines, the relationship between the
following parameters (all expressed per kg dry air) of a changing
mixture of dry air and water vapor:
 Absolute humidity (wVAP in kg vapor/kg dry air)
 Enthalpy (h in kJ/kg dry air)
 Dry-bulb temperature (q in  C)
 Wet-bulb temperature (qwb  C)
3741
 Dewpoint temperature (qdew in  C)
 Relative humidity (4 in %)
 Partial vapor pressure (pvap in kPa)
 Specific volume (v in m3/kg dry air)
If two of the eight parameters are known, the other six are given
by the Mollier chart.
The energy use of the drying process can be extracted from the
Mollier chart for humid air by plotting the conditions of supply (i1)
and exhaust air (u1) of the dryer. The energy use of water evapo-
ration is the product of the energy input per kg dry air and the
amount of dry air needed to remove the water (eq. (3)). The energy
input per kg dry air is the difference in energy content of supplied
and exhaust air (eq. (4)). The amount of air needed for 1 kg of
product water evaporation (PWE) is given by the difference in
absolute water content of the two streams (eq. (5)).
Energy use ðkJ=kg PWEÞ ¼ Energy input ðkJ=kg dry airÞ
*Air use ðkg dry air=kg PWEÞ ð3Þ
Energy input ðkJ=kg dry airÞ ¼ hexhaust  hsupply (4)
1000 g
Air use ðkg dry air=kg PWEÞ ¼ (5)
wVAPexhaust  wVAPsupply
where wVAPexhaust ¼ absolute humidity exhaust air (g water/kg dry
air); wVAPsupply ¼ absolute humidity supply air (g water/kg dry air).
3.3. Heat recovery
An important measure to increase energy efficiency in drying, is
for two applications to use recovered heat directly into the process:
(1) preheating incoming air and heating process water. Another option
is to use the heat for space heating (excluded here).
3.3.1. Preheat supply air
(2)
Energy from the exhaust air can be recovered to preheat the
supply air. The heat recovery efficiency is determined by
the temperature efficiency of the (aireair) heat exchanger. The
temperature efficiency gives the temperature change in each
stream as compared to the maximum temperature difference that
could be achieved if the exchanger had an infinite size. Tempera-
ture efficiency values are used to calculate the amount of heat
transferred in air to air heat recovery equipment:
where hq ¼ temperature efficiency of the heat exchanger;
m ¼ mass (kg); q ¼ temperature ( C); wVAP ¼ moisture content (g/
kg dry air); h ¼ enthalpy of the humid air (kJ/kg dry air); c ¼ specific
heat (kJ/(kg  C))
a) when: ma $ ca < mo $ co then
mo $co ðqo2  qo1 Þ
hq ¼ (6)
ma $ca ðqa1  qo1 Þ
3742 J. Laurijssen et al. / Energy 35 (2010) 3738e3750

Fig. 3. Principle of the Mollier chart for humid air.

b) when: ma $ ca  mo $ co then 3.3.2. Heating process water

If enough energy is available, energy from the exhaust air can be
mo $co ðqo2  qo1 Þ q  qo1 further used to heat the process water. Increasing process water
hq ¼ ¼ o2 (7) temperature could lower gross energy use since it lowers the
mo $co ðqa1  qo1 Þ qa1  qo1
viscosity of water. A lower viscosity leads to increased drain
Pre-heating of the incoming air with exhaust air is already common velocity in the wire and press section, resulting in higher dry matter
practice, the temperature efficiencies of heat exchangers in the content after the press section. A widely quoted rule of thumb for
paper industry are in practice seldom higher than 60% because of web heating is that for every 10  C increase in entry web temper-
economic reasons (the costs of heat exchangers increase with size). ature a 1% increase in dry matter content of the web can be
 J. Laurijssen et al. / Energy 35 (2010) 3738e3750
expected [21]. According to [19] this is usually quoted in combi-
nation with a second rule of thumb; for every 1% increase in solids
out of the press section a 4% energy savings or production increase
can be expected because of the reduced drier load. The 10  C rule of
thumb is often thought to be linear (within a specific range) for all
incoming solids and does not vary significantly across furnishes and
pressing conditions. However, in practice these rules may not hold
[22]. A review by [22] indicates, that for a 10  C change in web
temperature the change in outgoing solids ranges from 0.13 to 1.92
points. Moreover, this relationship changes as the solids content
change. The interaction between incoming solids, temperature
increase, and resultant change in web solids is not consistent.
Furnish, peak pressure, and pressure impulse have an effect on the
interaction. In general, for a given incoming temperature rise the
outgoing web solids increases as the temperature increases,
although sometimes the change is extremely small or the opposite
is true [22].
In this study we use the following assumptions (own assump-
tions but in principle based on the results in the review by [22]):.
Process-water from 40  C to 50  C, increase d.m. 1.5%, (steam
saving 6.0%)
Process-water from 50  C to 60  C, increase d.m. 1.3%,
(steam saving 5.2%)
Process-water from 60  C to 70  C, increase d.m. 1.1%, (steam
saving 4.4%)
Process-water from 70  C to 80  C, increase d.m. 0.9%, (steam
saving 3.6%)
Prerequisite for this assumption is that process water temper-
ature should be kept constant. With increasing process water
temperatures, the spontaneous water evaporation at the (open)
wire section increases. Therefore, with increased temperatures,
there is an increased cooling of water (by evaporation). This heat
loss should be compensated in order to keep the process water
temperature constant. The heat loss by spontaneous water evapo-
ration can be calculated as follows (see Eqs. (8) and (9)):
Heat loss ðMJ=hÞ ¼ wirewidth ðmÞ*spon evap ðt=h*mÞ
*evap heat ðMJ=tÞ ð8Þ
Evaporation heat ðMJ=tÞ ¼ 2501:6
 ð2:4*process water temp ð CÞÞ
(9)
where Heat loss ¼ energy loss by evaporation on the wire in MJ/h;
Wirewidth ¼ wirewidth in (m); spon_evap ¼ amount of water
evaporation on wire in t water per hour per m wire; evap_-
heat ¼ evaporation energy in MJ/t evaporated water; proc-
ess_water_temp ¼ temperature of the process water ( C).
3.4. Approach
In order to study the energetic optimization of ventilation
systems of conventional multi-cylinder dryers, we have used
a model based on thermodynamic principles. The model builds on
mass and energy balances of the paper web and the drying air (Eqs.
(8) and (9)). A similar approach has been chosen by [15,16]. We have
modeled a model paper mill using standard technology to calculate
energy use in the reference situation. Data for the model paper mill
are assumptions based on data from Dutch paper mills. No real time
experiments have been performed. We calculate net energy use for
drying a ton paper by multiplying water evaporation (kg PWE/t
paper) with energy use of water evaporation (MJ/kg PWE). The
3743
energy savings by heat recovery are also accounted for. Preheating
supply air lowers the energy use for water evaporation, heating
process water increases the dry matter content after the press
section and thereby decreases water evaporation per ton paper.
Several improvement options are identified that reduce the
amount of water evaporation, increase the efficiency of water
evaporation or increase the amount of heat recovered. The effect of
the improvement options on net energy use is calculated. We
further calculate total net energy savings that can be achieved by
combining all options.
4. Results
4.1. Reference situation energy use
The process conditions for the reference situation are given in
Fig. 4. We assume that the reference paper mill drying sections
operates at a dew point of 59  C, which is a common dew point
temperature in modern mills (compare with [15] that assumes an
average dew point of 60  C). The process water is not heated in the
reference situation. Due to pumps and other equipment the process
water temperature is higher than the outside water temperature; it
is here estimated at 40  C. The reference mill adds starch to the
paper in a size press. The starch comprises 3.5% of the final end
weight (bone dry). The starch has an 8% consistency. In the refer-
ence situation, only heat recovery for supply air heating is installed,
which is common in most mills. No heat recovery of process water
is installed.
The drying process is schematically depicted in the Mollier-chart
in Fig. 5. The exhaust air (u1) condition (temperature of 80  C and
relative moisture content is 40%) is plotted in Fig. 5. During drying,
the temperature of the air decreases (sensible heat) and at the same
time the moisture content of the air increases (latent heat). The sum
of sensible heat and latent heat does not change; this means that the
enthalpy stays constant during the drying process. The drying
process follows the line of constant enthalpy. Heating of the supply
air is a process that follows the line of constant absolute moisture
content. Outside supply air (i1) is first heated in HRC I. Assuming
supply air (i1) is 10  C, exhaust air (u1) is 80  C and temperature
efficiency of the heat exchanger is 45%. Preheating of the supply air
(i1ei2) can be calculated with equation (7): 0.45 ¼ (x  10  C)/
(80  C  10  C) / x ¼ 41.5  C. The temperature increases from 10  C
to 41.5  C while the absolute moisture content remains unchanged
(i2). The Mollier-chart shows that about 32 kJ/kg is transferred from
the exhaust air to the supply air. It is assumed that all exhaust air
(100%) is used to heat all supply air (100%). The supply air is further
heated in heat exchangers and by the cylinders. At the point of
junction between the line of heating and the line of drying, point i4 is
plotted, which indicates the required conditions of the drying air.3
The process water temperature is higher than 0  C; this means
that between i3ei4 no heating is required.
The amount of water evaporation in the pre-drying sections is
calculated with eq. (1) and the amount of water evaporation in the
final-drying section is calculated with eq. (2). The energy use per kg
PWE can be drawn from Fig. 5, using equations (3)e(5). The results
are shown in Table 2. The total drying energy is given by the total
evaporation per t paper multiplied with the energy use for
3
To describe the drying process in the Mollier-chart it is assumed that the
process takes place on one cylinder which can be heated till a very high temper-
ature (e.g. in “i4” the temperature is 430  C). In reality the drying section of a multi-
cylinder dryer is composed of several cylinders, and is therefore actually a sequence
of several smaller drying processes. However, this does not influence the results for
energy calculations.
3744 J. Laurijssen et al. / Energy 35 (2010) 3738e3750
Supply air:
Temp: 10°C
R.h.: 80%
HRC I :
HE
Temp: 95 °C
Process water
temp: 40°C Pre-dryer dew point 59°C
Paper web:
d.m. 48%
Steam
Fig. 4. Process conditions in the reference drying section.
evaporation. The calculated total drying energy in the reference
situation is 3.9 GJ/t paper.
4.2. Decreasing water evaporation
The amount of evaporated water per kg of final product is the
difference in dry matter content of the web before and after the
drying sections and the amount of water that added by means of
sizing, coating or gluing.
Decreasing the water evaporation in the drying section could be
achieved by:
a) increasing the dry matter content of the web before the first
dryer (dmi)
b) increasing the dry matter content before the final drying
section (dmifd)
c) decreasing the dry matter content of the final product (dmo)
(or by a combination of these options).
Option a) could be established by e.g. increasing the process
water temperature to increase dewatering in the wire and press
section (see below) or by increasing the performance of the press
section. Over the years, many improvements have been established
in the press section including the shoe press with extended nip as
one of the key improvements [23,24]. Therefore, we will not
investigate the latter option further in this study. Option c) is
a difficult option as it has a large influence on the paper quality and
end product specifications; we will not take these into consider-
ation. Here, we will focus on option b). The difference between the
dry matter content of the paper web after the pre-dryer section and
before the after-dryer section is caused by the addition of coating,
starch or glue (in a solution of water) in a size press in between the
drying sections.
4.3. Starch
In the case of starch, typically, size press additions involve re-
wetting the pre-dried paper on flooded rollers with a starch solu-
tion to soak the starch into the paper. Once soaked, the treated
paper is dried again, thereby providing paper of increased strength.
In the production of paper for corrugated board from recovered
paper, approximately 3.5% of the end weight of the product is
starch. Currently, starch is typically added in a solution with only 8%
= 45%
Starch:
Exhaust air: Amount: 3.5%
Temp: 80°C Consistency: 8%
R.h.: 40%
Final dryer dp: 59°C
d.m. d.m. 95 %
80 %
Condensate
dry matter content. This means that for every 100 t paper produced,
3.5 t starch is added in a solution of 40 t water, that needs to be
evaporated in the after-dryer section.
4.4. Coating
Coatings can constitute a large share of the total end weight of
the paper (e.g. up to 30%) Coatings are added to the paper in much
higher consistency than starch, typically 68% dry matter content.
This means that for every 100 t paper produced, 30 t coating is
added in a solution of 14 t water.
4.5. Glues
Glues are used to laminate board with a layer of paper. The
amount of paper added to the board can be a large share of the total
end weight of the product, but the glue is only 1.5% of the final board
mass (without paper additions). Glue is typically added to the board
in a solution of 30% dry matter content. This means that for every
100 t board produced, 1.5 t glue is added in a solution of 3.5 t water.
An option to decrease the amount of water evaporation (and
thus energy use) in the drying section would be to apply these
additives in higher consistencies. The highest potential is found in
the addition of starch as water input is largest in this case. In Fig. 6,
the energy use per t paper of the after-drying section is plotted
against the consistency of the additive. We assume an energy use of
2.8 GJ/t PWE in the drying section (reference situation). Fig. 6
shows an expected reduction in energy use with increasing
consistencies however, the energy saving potential decreases with
higher consistencies, as the water removal is inversely proportional
to the dry matter content of the starch solution. The largest energy
savings are realized in the first part of the graph; for increases in
dry matter content from 8% to around 30%, the energy saving in the
after-drying section is 0.9 GJ/t paper (i.e. more than 50% of the
energy use in the after drying section). Although the use of high
consistency sizing agents is not yet commercial, research is
currently being undertaken to develop economic viable high dry
content sizing and glue agents [25].
4.6. Decreasing energy use for water evaporation
In order to define the optimal drying conditions (i.e. with lowest
energy use) we have used the Mollier chart for humid air to find the
 J. Laurijssen et al. / Energy 35 (2010) 3738e3750 3745

Fig. 5. The reference drying process in the Mollier-chart.

3746 J. Laurijssen et al. / Energy 35 (2010) 3738e3750

Table 2
Total drying energy in the reference situation: input values and calculated results.

Variables Input Output

Parameter Unit Reference Calculated

assumption input values
dmi % 48
dmadp % 80
dmifd % 60.8a
dmo % 95
Pbdry t paper 1
PWEpd kg PWE/t dry paper 833b
PWEfd kg PWE/t dry paper 592c
PWEtotal kg PWE/t dry paper 1425
hexhaust kJ/kg dry air 440d
hsupply kJ/kg dry air 58d
WVAPexhaust kg vapor/kg dry air 144d
WVAPsupply kg vapor/kg dry air 6d
Energy input kJ/kg dry air 382e
Air use kg dry air/kg PWE 7.23f
Energy use GJ/t PWE 2.8g
evaporation

Drying energy GJ/t paper 3.9h

a
It can be calculated that 402 kg of water is used to add starch to 1 t paper. The
dry matter content after the size press decreases from 80% to 60.8%.
b 100  100 Þ  P
PWEpd ¼ ðdm dm bdry .
i apd
c 100  100 Þ  P
PWEfd ¼ ðdm dm bdry .
ifd o

d
Value can be drawn from Fig. 5.
e
Energy input (kJ/kg dry air) ¼ 440 kJ/kg dry air  58 kJ/kg dry air ¼ 382 kJ/kg dry
air.
f 1000 g
Air use ðkg dry air=kg PWEÞ ¼ WVAPexhaust WVAPsupply .
g
Energy use (kJ/kg PWE) ¼ Energy input (kJ/kg dry air) * Air use (kg dry air/kg
PWE).
h
The total drying energy is given by the total evaporation per t paper (kg PWE/t
dry paper) multiplied with the energy use for evaporation (MJ/kg PWE).
relation between the temperature of the exhaust air and the energy
use per kg water evaporation. This relation is shown in Fig. 7, where
also different dew point temperatures, relative humidity and
drying air temperatures are depicted. The supply air condition is set
at 10  C and 80% relative moisture content.
As can be seen from Fig. 7, point A indicates the conditions with
the lowest energy use per kg evaporated water. However, this point
is located on the pure vapor line where moisture content of the air
is 100% and drying will be impossible. In order to keep the drying
process at sufficient speed, the relative humidity of the air should
be around 40% at maximum [26]. It can be seen that the energy use
per kg evaporated water decreases with increasing temperature.
This may seem contradictory since higher temperatures demand
a higher energy use. However, following thermodynamic rules the
capacity of air to hold moisture increases exponentially with
increasing temperatures, meaning that much less air is needed to
evaporate a kg of water. Therefore, although the temperature
increases, the amount of air that needs to be heated decreases
Fig. 7. Energy use per kg water evaporation at different multi-cylinder dryer exhaust
air temperatures (adapted from [28]).
which results in a decrease in total energy use. This is validated by
our model. Hence, in theory, the optimal drying condition would be
a relative moisture content of around 40% with as high temperature
as possible (i.e. just above the pure vapor line). Current best
available dryers have guaranteed maximum dew points of 62  C
[15]. While some paper mills operate on higher dew point than
62  C, many paper mills with closed hoods have dryers with
operating dew points only around 55  C or even lower. A transition
from a dew point of 55  C to a dew point of 70  C would decrease
energy use per kg of water evaporation with more than 8%.
4.7. Combined energy saving potential including increased heat
recovery
Not only energy use in the drying section decreases with
increasing dew point temperatures, also the heat recovery potential
increases. An option to further recover heat from the exhaust air is
to first pre-heat the supply air of the drying section and to subse-
quently heat the process- and spray-water in a heat exchanger. In
this section, we estimate the combined effect of the above identi-
fied optimization options to reduce energy in the drying section.
Moreover, we include heat recovery for process water heating. The
process conditions are depicted in Fig. 8.
We assume (see Figs. 4 and 8) that the outside air conditions for
both the reference situation and the optimized situation are the same.
The exhaust air of the dryer in the optimized situation has the same
relative humidity as in the reference drying process (40%) but the
exhaust temperature is 92.6  C (instead of 80  C) which results in
a dew point of 70  C as compared to 59  C. The process water
temperature in the optimized situation is 55  C. The increase in
process water temperature from an average 40  C to 55  C increases
the dry matter content after the press section. Based on our
assumptions,4 we estimate that the dry matter content after the press
section increases from 48% to 50% due to increasing process

4
Process-water from 40  C to 50  C, increase d.m. 1,5%, (steam saving 6%);
Fig. 6. Energy use in the final drying section at different starch solution consistencies. Process-water from 50  C to 60  C, increase d.m. 1,3%, (steam saving 5,2%).
 J. Laurijssen et al. / Energy 35 (2010) 3738e3750
Supply air:
Temp:
10°C
HRC I : = 45%
HE
Temp: 95 °C
Process water
temp: 55°C Pre-dryer dew point 70°C
Paper web:
d.m. 50%
Steam
Fig. 8. Process conditions in the optimized situation.
temperature. The optimized drying process is schematically depicted
in the Mollier-chart in Fig. 9. Since the process water is heated to 55  C
in the optimized situation, we need to take into account the heat loss
by spontaneous water evaporation. The amount of water evaporation
in the drying sections is calculated with eq. (1) and eq. (2). The energy
use per kg PWE can be drawn from Fig. 9, using equations (3)e(5). The
heat loss and evaporation heat are calculated with equation (8) and
(9). Table 3 shows the input values and calculated results for energy
use in the optimized situation. The calculated total drying energy in
the optimized situation is 2.7 GJ/t paper.
The heat loss due to spontaneous water evaporation is
calculated at 0.4 GJ/t .We use Fig. 9 in order to check if the
exhaust air contains enough energy to compensate for the heat
loss due to spontaneous water evaporation. Fig. 7 shows that in
the exhaust air 0.4 GJ/t is available for this purpose. This means
that the heat losses can be completely covered with heat from
the exhaust air.
4.8. Summary of results
Comparing the results of the reference drying process and the
optimal drying process including all proposed measures gives the
results as reflected in Table 4.
The heat saving due to the optimization actions of the drying
section is 1.3 GJ/t paper, or 32% compared to the reference situation.
Part of the savings are the result of increased dew point of the dryer,
that results in a lower air use and increased dryer efficiency. Most of
the savings are however due to reductions in the amount of water
evaporation. This is partly the result of increased consistency in
starch additives (final dryer) and partly due to increased process
temperatures (pre-dryer). The increased process temperature
became possible due to a higher dew point temperature in the
dryer hood, which increased heat recovery potential.
5. Discussion
This study has shown that there is large energy saving potential
in multi-cylinder dryers. Only heat savings were taken into account.
It is however expected that as a result of a decreased air flow in the
drying section, electricity use will also decrease. We did not take
into account the effect on the drying rate. The drying rate is
dependent on the heat conductivity in the drying cylinders. The
energy for paper drying comes from steam inside the drying
3747
HRC II Process water:
Temp: 55°C
Starch:
Exhaust air: Amount: 3.5%
Temp: 92.6°C Consistency: 30%
R.h.: 40%
Final dryer dp: 70°C
d.m. d.m. 95 %
80 %
Condensate
cylinders, which partly condensates and releases condensation
heat. One of the most important thermal resistances during heat
transfer is the condensate layer on the inside of the cylinder, of
which the thickness can be controlled by water removing siphons.
The thermal conductivity of the water layer can be increased by e.g.
the application of spoiler bars that are used to induce turbulence in
the condensate layer. The main purpose of implementing these bars
is to improve the uniformity and rate of heat transfer (drying rate)
of the dryers. They can be used to either increase productivity or to
use lower operating steam pressures while maintaining the same
paper production rates. The amount of energy needed to evaporate
water, however, is not dependent on the heat conductivity and this
will therefore not impact our results.
Water in a moist paper web consists of different fractions: free
water in between the fibers and in large pores, and bound water
(micro-capillary moist). The fractions differ in their thermody-
namic properties. Most of the water removed in the drying section
of a paper machine is free water. Only when the paper web’s
moisture ratio decreases below approximately 30%, most of the free
water has been evaporated and the remaining part is bound water
[5]. For evaporation of bound water an extra amount of energy
(which is called heat of sorption) is necessary besides the latent
heat of vaporization for free water. In this study we have not taken
into account the heat of sorption as it is only a small (approximately
1%) fraction of the total energy use in the dryer [5]. However, it
increases exponentially with decreasing moisture content of the
paper web. Drying to very low moisture contents should therefore
be avoided. Also fiber selection can play a role in energy efficiency
improvements in a paper mill [27]. The water retention value
(WRV) of fibers indicates the ability of fibers to hold (free) water.
The lower the WRV, the better the dewatering in the wire and press
sections. This indirectly influences drying energy as less water
needs to be removed thermally. The WRV depends mainly on the
external and internal fibrillation of fibers and on the absence/
presence of fines. Different fiber species (e.g. softwood/hardwood)
can have different WRVs. Moreover, the WRV can be increased by
refining (beating of the fibers to increase strengths properties) or
decreased by the treatment with enzymes. The use of (chemical)
retention agents is already widely used in the paper an board
industry to increase the dewatering of the fibers in the wire and
press section. The WRV of fibres impacts wire and press dewater-
ing, and hence the dry matter content before the press section; it
does not impact the drying efficiency.
3748 J. Laurijssen et al. / Energy 35 (2010) 3738e3750

Fig. 9. The optimised drying process in the Mollier-chart.

 J. Laurijssen et al. / Energy 35 (2010) 3738e3750 3749

Table 3 Table 4
Total drying energy in the optimized situation: input values and calculated results. Summarized results: water evaporation and heat use in the reference and optimized
situation.
Variables Input Output
Reference Optimal
Parameter Unit Assumption Calculated
situation situation
input values

Heat use per t PWE 2.8 GJ/tPWE 2.6 GJ/tPWE
Processwater C 55
Water evaporation 833 kg PWE/t paper. 750 kg PWE/t paper
temperature
pre-dryer
Evaporation heat GJ/t 2.4
Water evaporation 592 kg PWE/t paper. 270 kg PWE/t paper.
Wirewidth m 6a
final dryer
Spontaneous water t H2O/(h*m) 2b
PWE total 1425 kg PWE/t paper 1020 kg PWE/t paper
evaporation
Heat use 3.9 GJ/t paper 2.7 GJ/t paper
Heat loss (GJ/h) 28
per t bone dry
Heat loss (GJ/t dry air) 0.4c
product
dmi % 50d
dmadp % 80
dmifd % 75.6e
dmo % 95 effect of increased water temperatures on the dry matter content is
Pbdry t paper 1 therefore needed. Moreover, there could be possible disadvantages
PWEpd kg PWE/t dry paper 750f of high process water temperatures like higher wastewater
PWEfd kg PWE/t dry paper 270g temperatures (energy loss), higher pipe temperatures (safety),
PWEtotal kg PWE/t dry paper 1020
hexhaust kJ/kg dry air 772h
increased contamination of press felts, extra maintenance, and air in
hsupply kJ/kg dry air 64h process water. On the other hand, there could be possible advantages
WVAPexhaust kg vapor/kg dry air 277.5h besides steam savings in the drying section, like lower specific
WVAPsupply kg vapor/kg dry air 6.1h energy consumption for pulping and vacuum, lower biological
Energy input kJ/kg dry air 709i
activity in the process water circulation loop and lower specific
Air use kg dry air/kg PWE 3.68j
Energy use GJ/t PWE 2.6k water consumption. It is recommended that the possible side-effects
evaporation of increased process water temperatures are studied further.
Total drying GJ/t paper 2.7l
The other proposed optimization measures could also have side-
energy effects. If the air flow in the dryer is reduced, it might decrease the
a ability of the paper web to stay connected to the cylinder’s surface.
The width of the paper web in the paper machine ranges from over 2 to 12 m
(Van Lieshout, 2006). We have chosen an average wire width of 6 m in this example. Therefore, extra equipment to circulate the air internally might
b
According to Metso, the wire section exhaust for a newsprint machine with need to be installed. A positive side-effect of the increased exhaust
a wire width of 10 m and 1800 m/min machine speed, contains 61 g H2O/kg dry air. temperature and smaller air volumes is that the heat recovery
99 kg dry air/s is released into the machine room. Compared to outside air (moisture equipment can be much smaller than with larger air volumes,
content of approximately 6 g H2O/kg dry air, see Fig. 5). The water uptake is 55 g/kg
dry air. The water evaporation is then 99 * 55 ¼ 5.5 kg/s for 10 m wire width. This is
which reduces the investment costs of this type of equipment
0.55 kg H2O/(s * m) or 2.0 t H2O/(h * m). significantly. An overall side-effect of heat reduction is that for
c
Product water evaporation (PWE) ¼ (100/50e100/95) * 20 t/h ¼ 18.9 t PWE/h; existing mills, the CHP plant is optimized for the mills’ specific heat
Heat loss by spontaneous evaporation per ton PWE ¼ 2.8*10^4 MJ/h:18.9 t PWE/ demand. A decreasing heat demand could results in less optimized
h ¼ 1.5 GJ/ton PWE; Heat loss per kg dry air ¼ 1.5 GJ/ton PWE: 3.68 kg dry air/kg
operation of the CHP plant and could therefore have a significant
PWE [ 0.4 GJ/t dry air.
d
The increase in process water temperature from an average 40  C to 55  C impact on the efficiency of the CHP plant.
increases the dry matter content after the press section from 48% to 50%. n this study, several options for heat savings in the drying
e
Starch comprises 3.5% of the final end weight (bone dry) so for 1000 kg paper, section of conventional multi-cylinder dryers in the paper industry
35 kg starch is added. We assume starch is added in 30% consistency. In that case, have been identified. The influence of these measures on the
82 kg of water is used to add starch. The dry matter content after the size press is
calculated to be 75.6%.
operating performance and/or product quality are however
f
PWEpd ¼ ðdm 100  100 Þ  P
bdry .
uncertain. Moreover, the cost effectiveness of the different
i dm apd

g 100  100 Þ  P measures is unknown and will probably differ largely from case to
PWEfd ¼ ðdm dm bdry .
h
ifd o
case. The costs of a drying hood depend largely on scale, machine
Value can be drawn from Fig. 9.
i type, product produced and on the currently installed dryer and its
Energy input (kJ/kg dry air) ¼ 770 kJ/kg dry air  60 kJ/kg dry air ¼ 710 kJ/kg dry
air. technical age. The same is valid regarding heat recovery equipment.
1000 g
j
Air use ðkg dry air=kg PWEÞ ¼ WVAPexhaust WVAPsupply .
Because the options discussed are mainly retro-fit solutions, it is
k
Energy use (kJ/kg PWE) ¼ Energy input (kJ/kg dry air) * Air use (kg dry air/kg hardly possible to estimate the effect on costs. The high-consis-
PWE). tency starch solutions are not commercially available yet, which
l
The total drying energy is given by the total evaporation per t paper (kg PWE/t makes it impossible to give cost figures also on this option.
dry paper) multiplied with the energy use for evaporation (MJ/kg PWE). Therefore, although a large energy saving potential has been
identified, further research and practical tests are required. These
As indicated, the higher the dry solid content of the paper web should make clear if the potential could be fully exploited.
after the press section, the smaller the energy use in the drying
section. The efficiency of press section water removal is dependent
on several factors: e.g. the WRV of the fibers, the ash content of the 6. Conclusion
furnish, the construction/design of the press (e.g. the residence time
in the press, the applied pressure and the quality of the press felt) The paper industry is, with about 6% of total worldwide indus-
and the temperature of the process water. In this study, we only trial energy use, an energy-intensive industry. The drying section, is
investigated the effect of increased process water temperature on with about 50% the largest energy user in the papermaking process
drying section energy use. Increasing process water temperature is (excluding pulping). Energy use in the drying section is mainly heat
assumed to have a positive effect on the dry matter content after the use. In this study, several options to decrease heat use in the drying
press section [21,22], however, information and practical studies on sections have been investigated and the combined effect of these
the precise relationship are scarce. More information about the optimization measures has been calculated.
3750 J. Laurijssen et al. / Energy 35 (2010) 3738e3750
The energy use to evaporate water can be decreased by
increasing the temperature in the dryer. A transition in dew point
from 55  C to 70  C decreases energy use of water evaporation with
more than 8%. The relative moisture content of the exhaust air
should with this measure be kept around or below 40% in order to
keep the drying capacity. Increasing the temperature also increases
the heat recovery potential of the exhaust air. Heat from the
exhaust air can first be used to pre-heat the incoming air of the
dryer and then to increase the process water temperature. An
increase in process water temperature from an average 40  C to
55  C is assumed to reduce steam use with about 8% due to better
dehydration on the wire. The third optimization measure aims to
decrease the amount of water evaporation in the drying section by
applying additives in higher consistencies. The highest potential is
found in the addition of starch as water input is largest in this case.
For increases in dry matter content from 8% to around 30%, the
energy saving in the after-drying section is approximately 0.9 GJ/t
paper (i.e. more than 50% of the energy use in this section).
The combined heat saving potential due to the optimization
actions in the drying section is 1.3 GJh/t paper (or 32%) as compared
to the reference situation. This is a saving of about 15% of the total
primary energy use in the paper mill. These savings are consider-
able and could not only contribute to the mills’ competitiveness, as
energy costs have become one of the key cost components of the
pulp and paper sector, they also contribute to the energy efficiency
targets of the national and European governments. The main
uncertainties in this study are the influence of the optimization
options on the operating performance and/or product quality and
the effect of increased process water temperature on water removal
in the press section. Moreover, the cost effectiveness of the
different measures is unknown and will probably differ largely
from case to case. Furthermore, the use of high consistency starch
additives is not commercial yet, but R&D in this field is currently
ongoing. Research and implementation by trials is recommended to
investigate the side-effects of the proposed measures and to
identify if the heat saving potential could be fully exploited.
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